CN102637020B - A kind of steel rolling heating furnace integrated control system - Google Patents

Abstract

The present invention relates to a kind of steel rolling heating furnace integrated control system, comprise: supervisory computer system [101], slip-stick artist's controller [102], operator's computing machine [103], computing machine gateway [104], monitor network [105], field-bus interface [106], fieldbus networks [107], fieldbus instrument and utility appliance [108], it is characterized in that, supervisory computer system also comprises: working of a furnace diagnostic module, steel billet temperature control module, furnace temperature temperature rise Optimal Control module, in order to realize the working of a furnace diagnosis of heater for rolling steel production run, steel billet temperature controls, furnace temperature temperature rise Optimal Control, level of integrated system is high, the control method that native system provides, by multiple-model integration, carries out information fusion, realizes system high control strategy, and be optimized, cooperation control, also can the heating furnace working of a furnace be diagnosed, forecasts and be analyzed, guarantee safe production.According to system provided by the present invention, in complex situations, effectively can carry out Comprehensive Control to heater for rolling steel production run, improve production efficiency and heating steel billet quality, reduce energy consumption, ensure that heating furnace runs with security and stability, thus reach the heater for rolling steel productive target of " high-quality, low consumption, high yield " and the control criterion of " safety, stable, equilibrium ".

Description

A kind of steel rolling heating furnace integrated control system

Technical field

The present invention relates to Process Control System, particularly relate to heater for rolling steel industries process control system, and relate more specifically to a kind of steel rolling heating furnace integrated control system.

Background technology

Heater for rolling steel production run is an important step in Rolling production process, the quality of its heating steel billet quality, directly affects steel and to become a useful person quality.Because heating furnace production run is a very complicated industrial process, all the time, many experts, scholar and numerous engineering technical personnel are in the research being devoted to the control of heater for rolling steel production run, the production run grasp the working of a furnace to reach, automatically controlling heater for rolling steel, the object of improving the quality of products.

Current heater for rolling steel control system many employings conventional control instrument and equipment and traditional industrial control unit (ICU), these traditional production run control device, conventional control method is adopted to carry out the control of heating furnace production run, because its functional structure is single, reliability, interchangeability are poor, difficult in maintenance, have impact on the control effects of production run.And the temperature of heating furnace controls mostly to adopt furnace temperature as heating steel billet measure of effectiveness standard, steel temperature is represented by furnace temperature, temperature controls inaccurate, heating steel billet effect is difficult to hold, and then affect the rolling quality of steel billet, simultaneously again according to the control micro-judgment heating furnace production status of site operation personnel, cannot ensure that heating furnace runs with security and stability completely effectively.

In view of the high complexity of heater for rolling steel production journey, the optimal control of heater for rolling steel production run be reached, adopt model information single at present and existing control mode cannot reach desirable control effects.An effective steel rolling heating furnace integrated control system integratedly should organize different Controlling model more, thus provides best operation scheme, reaches the target of Increasing Production and Energy Saving safety.

Summary of the invention

The technical problem to be solved in the present invention is, for the feature such as complicacy, uncertainty of heater for rolling steel production run, and the limitation of existing control technology and method existence, adopt the control method based on integrated-type to carry out the control of heater for rolling steel production run, thus reach the heater for rolling steel productive target of " high-quality, low consumption, high yield " and the control criterion of " safety, stable, equilibrium ".

For achieving the above object, the invention provides a kind of heater for rolling steel industries process control system FCS based on integrated-type, FCS system forms field control layer by fieldbus instrument FD, fieldbus networks FNET, fieldbus utility appliance and field-bus interface FBI, system monitoring layer is formed by supervisory computer system SCS, operator's computing machine OS, slip-stick artist's controller ES, monitor network SNET, computing machine gateway CG etc., it is characterized in that, this system for field bus control system FCS is a distributed network control system, and it comprises:

FD fieldbus instrument and equipment, include: signals collecting transmitter, actuator and signal converter, for the collection of heater for rolling steel control signal data, input, output, computing, control with communicate, and functional block is provided, so that composition control loop in bus at the scene, form a distributed network control system.

(1) signals collecting transmitter

Signals collecting transmitter has the signal supervisory instrument such as temperature, pressure, flow, liquid level that heater for rolling steel is conventional, be made up of instrument circle card and bus circle card, instrument circle card completes sensor signal and amplifies and conversion, and by interface bus and bus circle card exchange information.Also have A/D conversion and interface circuit in addition, carry out the analog to digital conversion of collection signal, bus circle card realizes field bus protocol FF-H1 and the round exchange information of blocking of instrument, by bus interface and field bus communication, transform block is provided, Resource Block and functional block, adopt integrated circuit (IC) chip (ASIC), CPU, bus interface circuit and with instrument circle block the interface circuit forming exchange information, the application function of field bus protocol FF-H1 is realized by CPU software programming in bus circle card, the driving of the bus signals needed for Physical layer and data link layer is realized by integrated circuit (IC) chip (ASIC), send, the acceptance of signal, serial/parallel or the parallel/serial conversion of transmission data, the Code And Decode of serial data, the packing of information frame and unpacking, the functions such as the generation of Frame Check Sequence and verification.

(2) actuator

Actuator has electric control valve and pneumatic control valve.Be made up of instrument circle card and bus circle card, instrument circle card is for signal conversion and drives, and by interface bus and bus circle card exchange information, D/A conversion and interface circuit, carry out the digital-to-analog conversion of control signal, bus circle card realizes field bus protocol FF-H1 and the round exchange information of blocking of instrument, by bus interface and field bus communication, transform block, Resource Block and functional block are provided, adopt integrated circuit (IC) chip (ASIC), CPU, bus interface circuit and block with instrument circle the interface circuit forming exchange information.

(3) signal converter

Signal converter is used for the conversion of the signal between traditional analog instrument and fieldbus numeral instrument, mainly: a) receive 4mA ~ 20mADC current signal, then converts thereof into the applicable signal of FF-H1; B) receive the digital signal of FF-H1, then convert thereof into 4mA ~ 20mADC current signal.Traditional analogue instrument is made progressively to the transition of fieldbus numeral instrument by converter.

Fieldbus instrument has resource module, conversion module and functional module, resource module includes the characteristic such as type, memory size of equipment, conversion module includes the I/O characteristic of equipment, for from sensor reading certificate or to actuator issue an order, for functional module application provides interface.There is containing parameter in system in the parameter list of resource module and conversion module, without input and output parameter, the configuration of control loop can not be carried out.Functional module includes input, output, computing and control function block, form parameters input, parameter output, algorithm, interior containing parameter, incoming event and outgoing event, owing to there being input and output parameter, the configuration of heater for rolling steel production run control loop can be carried out.

The formation in Fieldbus Control loop is exactly the connection in fieldbus instrument between functional block, usually could form a control loop by the functional module of several fieldbus instruments, both can form simple control loop, and also can form complex control loop.For this reason, can first carry out connecting configuration between functional module with configuration software, form configuration file, then configuration file is downloaded in each fieldbus instrument, set up the annexation between functional module; In last bus at the scene, scheduling forms each functional block operation of control loop, carries out the Parameter transfer between functional module.

Fieldbus utility appliance has bus power source, source impedance conditioner, intrinsic safety barriter, terminal organ, repeater and bridge.

(1) bus power source: be used for as bus or field instrument are powered.

(2) source impedance conditioner: present high impedance to digital signal, prevents digital signal by bus power source short circuit.

(3) intrinsic safety barriter: it is the isolator of harbor and hazardous area.

(4) terminal organ: be used in the head end of transmission cable and the impedance matching box of end, terminal organ can prevent signal transmission distortion and bus two ends from producing signal wave reflection.

(5) repeater: be used for extending fieldbus segment.Repeater is an active Bus Powered Device or non-bus power-supply unit.

(6) bridge: for connecting the fieldbus segment of different transmission rates, or the network segment of different transmission medium is linked to be network.

SCS supervisory computer system is used for setting up fault diagnosis model, steel billet temperature Controlling model, the furnace temperature temperature rise optimizing control models of heater for rolling steel production run, various model carries out information fusion, the foundation of database, knowledge base, renewal and maintenance, realize advanced process control strategy, the optimization of system and cooperation control, and working of a furnace diagnosis, forecast and analysis can be carried out to heating furnace production run, guarantee safe production.

OS operator's computing machine is used for the operation of heater for rolling steel production run, supervision and management.For system provides heating furnace production run man-machine interface (MMI), the picture provided for user is divided into general picture, special picture and supervisory frame etc., wherein general picture has heating furnace production run overview panel, a series of paintings face, point picture, trend picture, alarm screen etc., special picture has heating furnace production run main menu, data acquisition system (DAS) picture, Operating Guideline picture, control loop picture etc., supervisory frame has operator's operation note, process point alarm logging, system equipment status record, system equipment error logging, system equipment status, functional block gathers picture etc.Under the support of configuration software, first user draws and configuration heating furnace production run picture, then picture file is downloaded to operator's computer run, operates for process operator, monitors and manages heating furnace production run.

ES slip-stick artist's controller, carries out system generation and maintenance for field engineer to FCS, provides the establishment of the drafting of control engineering Shi Jinhang control loop configuration programming, man-machine interface, report making and special applications software.

FBI field-bus interface, has Cardbus NIC Cardbus and interchanger, under connect FNET fieldbus, on connect SNET monitor network, thus realize being interconnected of FNET fieldbus and SNET monitor network.

FNET fieldbus networks, under connect FD fieldbus instrument and equipment, on connect FBI field-bus interface, carry out the exchange of on-site signal and control signal.

SNET monitor network, for connecting FBI field-bus interface, OS operator's computing machine, ES slip-stick artist's controller, SCS supervisory control comuter and CG computing machine gateway, carries out Signal transmissions.

CG computing machine gateway, for connecting monitor network and production management network, realizes the intercommunication mutually between them.

By networking field bus control system FCS, control in order to realize steel rolling heating furnace integrated production run.

Because FCS system is a distributed network control system, Signal transmissions achieves total digitalization, pass through fieldbus, both the data of fieldbus intra-node can have been shared, also the functional block of fieldbus intra-node can be shared, at the scene bus is convenient to composition heating furnace production run control loop, achieves " namely connect and namely use " and the information sharing of decentralised control thoroughly and fieldbus.

This systemic-function is comprehensive, integrated level, reliability are high, interchangeability good, antijamming capability is strong, maintenance is easy, install and use the features such as expense is low, and can effectively improve heater for rolling steel production efficiency, system reaches good level of control.

For the control method of steel rolling heating furnace integrated control system, by heater for rolling steel production run working of a furnace diagnostic model, steel billet temperature Controlling model, the multiple Controlling model of the best Temperature Rise Model of heating furnace is integrated forms, and comprises the following steps:

1) heater for rolling steel production run working of a furnace diagnostic model is analyzed; 2) foundation of steel billet temperature Controlling model; 3) operation of the best Temperature Rise Model of heating furnace.

Technical scheme: heater for rolling steel working of a furnace diagnostic reasoning model is native system important component part, is only ensureing just to be optimized control to heater for rolling steel process under the condition that heater for rolling steel is stable.Because the many operating experience many genus causalities diagnosed for the heater for rolling steel working of a furnace judge, therefore heater for rolling steel working of a furnace diagnostic model mainly adopts fuzzy logic inference method.

We adopt the method establishment Fuzzy Inference Model based on Takagi-Sugeno fuzzy rule, and its advantage to utilize less rule to describe the nonlinear system of high complexity, and the single order T-S fuzzy model based on K rule is as follows:

R _i：IFx ₁isA _i1And…Andx _jisA _ijAnd…Andx _misA _im，Theny _i＝a _iz+b _i(1)

Z=[x in formula ₁..., x _j..., x _m] ^t, a _i=[a _i1... a _ij... a _im], i=1,2 ..., K; J=1,2 ..., m, R _irepresent the i-th rule, x _jrepresent the fuzzy subset of a jth input variable, y _irepresent the output valve of the i-th rule, a _i, b _ifor unknown parameter.

The output of T-S model, namely T-S fuzzy system defuzzifier is:

$\tilde{y}=\frac{\underset{i=1}{\overset{K}{\mathrm{\Σ}}}{\mathrm{\γ}}_i\left(z\right)y_i\left(z\right)}{\underset{i=1}{\overset{K}{\mathrm{\Σ}}}{\mathrm{\γ}}_i\left(z\right)}=\underset{i=1}{\overset{K}{\mathrm{\Σ}}}{\mathrm{\ω}}_i\left(z\right)(a_{i}z+b)---\left(2\right)$

${\mathrm{\ω}}_i\left(z\right)={\mathrm{\γ}}_i\left(z\right)/\underset{i=1}{\overset{K}{\mathrm{\Σ}}}{\mathrm{\γ}}_i\left(z\right)---\left(3\right)$

Wherein γ _iz () is the contribution rate that the i-th rule exports for T-S model, ω _iz () is normal contribution.

Concrete steps are as follows:

(1) determine the input of Fuzzy Inference Model, output variable, namely selecting according to expertise and calculating affects larger variable as input variable for each concrete working of a furnace, and concrete working of a furnace grade is as output variable;

(2) each input, the variation range of output variable, quantification gradation and quantizing factor is determined;

(3) in the quantized field of each input and output linguistic variable, fuzzy subset is defined;

(4) T-S model is utilized to obtain the correlation parameter of model;

(5) defuzzification obtains concrete working of a furnace grade as output.

So far, a complete fuzzy control table is set up.Once detect out of order high-risk grade, working of a furnace diagnostic system just provides alarm, provides concrete operation measure for operating personnel according to expertise simultaneously.Compared to additive methods such as neural networks, T-S model can detect fault more accurately, and the working time simultaneously needed is less, also achieves good effect in actual applications.

And when production is normally carried out, will be optimized control to heater for rolling steel production run temperature, and reach the control effects of desirable steel billet temperature of coming out of the stove, the foundation of its steel billet temperature Controlling model, be the key of problem.

Steel billet temperature Controlling model is made up of basic steel billet Temperature Control Model and adjustment Correction and Control model two parts:

(1) foundation of steel billet temperature Controlling model.

According to calorifics formula, a given regretional analysis, the furnace temperature given by standard and various steel billet thickness and time inside furnace carry out the calculating of steel billet cardinal temperature parameter, and carry out regretional analysis by this result, Confirming model basic parameter, sets up the temperature controlled basic model of basic steel billet thus.

In heating furnace, be there is following relation by the temperature of heating steel billet and soaking zone furnace temperature, steel billet time inside furnace:

Q _m＝S _z-B ₀e ^-AX(4)

In formula: Q _mthe medial temperature of-steel billet; S _zthe mean value of the upper and lower furnace temperature of-soaking zone; X-time inside furnace;

B ₀-constant; A-coefficient.

In fact affect the temperature factor of steel billet, except time inside furnace, it is also relevant with steel billet thickness.

The relation of steel billet thickness and coefficient A:

A＝c·h ⁿ(5)

In formula: the thickness of h-steel billet; C, n-constant.

Taken the logarithm in (5) formula both sides:

lnA＝nlnh+lnC(6)

Regression equation for regression coefficient A:

lnA＝α ₁lnh+α ₃t+α ₂lnt+α ₄(7)

:

A＝h ^α1·t ^α3·e ^α2t+α4(8)

Time inside furnace is represented, S with t _z-Q ₀the B of substitution formula (4) ₀, obtain:

Q _m＝S _z-(S _z-Q ₀)e ^-At(9)

$e^{-\mathrm{At}}=-\frac{Q_m-S_Z}{S_z-Q_0}---\left(10\right)$

Formula (8) is substituted into formula (10) obtain:

$\begin{array}{c}\frac{S_z-Q_m}{S_z-Q_0}=e^{-(\mathrm{h\α}1\•t^{\mathrm{\α}3+1}}\exp ({\mathrm{\α}}_{2}t+{\mathrm{\α}}_4)\·t\\ =\exp \{-h^{\mathrm{\α}1}\·t^{\mathrm{\α}3+1}\·\exp ({\mathrm{\α}}_2\·t+{\mathrm{\α}}_4)\}\end{array}---\left(11\right)$

Are taken the logarithm in formula (11) both sides:

$\ln \frac{S_z-Q_m}{S_z-Q_0}=-[h^{\mathrm{\α}1}\·t^{\mathrm{\α}3+1}\·\exp ({\mathrm{\α}}_{2}t+{\mathrm{\α}}_4)]---\left(12\right)$

$\ln \left(\ln \frac{S_z-Q_m}{S_z-Q_0}\right)=-[{\mathrm{\α}}_1\·\ln h+{\mathrm{\α}}_{2}t+({\mathrm{\α}}_3+1)\·\ln t]---\left(13\right)$

Select the steel billet thickness that adapts with concrete heating furnace and time inside furnace to combine, calculate the medial temperature of steel billet by analytical model, and with replacement (13) formula in Q _m, then the S in formula (13) is replaced with the soaking zone standard furnace temperature suitable for this heating furnace _z, the factor alpha in (12) formula ₁~ α ₄.

Finally obtain the essential part of steel billet temperature Controlling model:

Q _m＝S _z-(S _z-Q ₀)·exp{-h ^α1·t ^α3+1·exp(α ₂t+α ₄)}(14)

For the determination of model parameter, to carry out according to on-the-spot knowledge such as the usable range of the characteristic of heating furnace, thermal regulation, slab thickness and steel billet and possible time inside furnaces, ask factor alpha with regression analysis ₁~ α ₄, these coefficients are substituted into (14) formula, under given furnace temperature, the steel billet medial temperature of any thickness and time inside furnace can be calculated.

(2) again according to the content of on-the-spot real-time data base, combine in conjunction with various steel billet thickness and time inside furnace, calculate the modified value of each section of furnace temperature, draw adjustment and the retouch of Controlling model.

Essential part due to Controlling model carries out steel billet temperature calculating under a certain fixing standard temperature, each section of desired temperature has direct impact to steel billet temperature, the actual model used must adapt to the many variations of each section of furnace temperature setting value, and obtain the change of the steel billet temperature caused thus, therefore must above model be adjusted and be revised.

Because heating furnace is generally made up of four sections, and each section design temperature has impact in various degree to steel billet temperature, therefore the model of retouch must comprise the amendment type of corresponding four sections, and formula (15) below can be adopted as the adjustment retouch of model:

ΔQ _m＝ΔHZ ₁(β ₁+β ₂·h+β ₃·t+β ₄·h·t)+

ΔHZ ₂(β ₅+β ₆·h+β ₇·t+β ₈·h·t)+

ΔHZ ₃(β ₉+β ₁₀·h+β ₁₁·t+β ₁₂·h·t)+

ΔHZ ₄(β ₁₃+β ₁₄·h+β ₁₅·t+β ₁₆·h·t)+β ₁₇(15)

In formula: Δ Q _mafter the change of-set temperature value, the undulating quantity of steel billet temperature; T-time inside furnace; H-steel billet thickness;

Δ HZ1-preheating section design temperature changing value; Δ HZ2-mono-bringing-up section design temperature changing value;

Δ HZ3-bis-bringing-up section design temperature changing value; Δ HZ4-soaking zone design temperature changing value;

β ₁~ β ₁₇-coefficient.

Due to adjustment retouch, it will adjust the change of the steel billet temperature that modifying factor change setting furnace temperature causes, so the scheme of furnace temperature adjustment first will be solved, in conjunction with the knowledge of database, steel billet thickness and time inside furnace can be selected to carry out different combinations, then the calculating of steel billet temperature is carried out, steel billet temperature when combining with corresponding slab thickness during standard furnace temperature and time inside furnace again asks poor, just obtain the influence amount to steel billet temperature when design temperature fluctuates, design temperature before and after steel billet temperature variable quantity corresponding for these schemes and change is substituted into formula (15), carry out recurrence to calculate, can obtain adjusting the factor beta with retouch ₁~ β ₁₇.

(3) formation of steel billet temperature Comprehensive Control model.

The final form of steel billet temperature Controlling model is made up of above-mentioned essential part and adjustment retouch, namely

$\begin{array}{c}T=\frac{1}{2}(S_{\mathrm{ZU}}+S_{\mathrm{ZL}})-[\frac{1}{2}(S_{\mathrm{ZU}}+S_{\mathrm{ZL}})-Q_0]\\ \×\exp \{-H^{A1}\·t_{\mathrm{TS}}^{A2}\·\exp (A_3\·t_{\mathrm{TS}}+A_4)\\ +\mathrm{\ΔHZ}1\·({\mathrm{\β}}_1+{\mathrm{\β}}_2\·H+{\mathrm{\β}}_3\·t_{\mathrm{TS}}+{\mathrm{\β}}_4\·H\·t_{\mathrm{TS}})\\ +\mathrm{\ΔHZ}2\·({\mathrm{\β}}_5+{\mathrm{\β}}_6\·H+{\mathrm{\β}}_7\·t_{\mathrm{TS}}+{\mathrm{\β}}_8\·H\·t_{\mathrm{TS}})\\ +\mathrm{\ΔHZ}3\·({\mathrm{\β}}_9+{\mathrm{\β}}_{10}\·H+{\mathrm{\β}}_{11}\·t_{\mathrm{TS}}+{\mathrm{\β}}_{12}\·H\·t_{\mathrm{TS}})\\ +\mathrm{\ΔHZ}4\·({\mathrm{\β}}_{13}+{\mathrm{\β}}_{14}\·H+{\mathrm{\β}}_{15}\·t_{\mathrm{TS}}+{\mathrm{\β}}_{16}\·H\·t_{\mathrm{TS}})+{\mathrm{\β}}_{17}\end{array}$

In formula: S _zU, S _zLthe top and the bottom reference temperature of-soaking zone; Q ₀steel billet temperature during-shove charge; H-steel billet thickness; t _tS-time inside furnace; Δ HZ1, Δ HZ2, Δ HZ3, Δ HZ4-are respectively the difference of each section of design temperature and reference temperature, that is: Δ HZi=T _ai-T _bi, wherein: T _aifor the design temperature of this section; T _bifor the reference temperature of this section; I=1 ~ 4 are segment number.

The rolling temperature that system can require according to roll line, determines steel billet tapping temperature, and provides by the good steel billet of this heating temperatures to roll line.The steel billet of the target temperature reached is provided in time to roll line and to greatest extent under fuel-saving prerequisite, each section of temperature control system to heating furnace exports the desired temperature calculated in guarantee.Temperature control of heating furnace is then optimized control by this temperature, makes the desired value that steel billet tapping temperature reaches required.

Carry out heater for rolling steel production run temperature Optimal Control, be exactly want furnace temperature to rise with the fastest speed, need on the one hand to supply enough fuel (heavy oil and gas), suitable air to be supplied simultaneously, make fuel just can Thorough combustion, burned many, lack of air or burn less, air excess all can not obtain the fastest rate of rise in temperature.

In whole Furnace Production Process, need to go to regulate according to fuel at that time, air conditions, fuel/air mixture is combined and is in optimum condition all the time, just can obtain higher temperature rise speed.

In native system adjustment process, the situation that heating furnace is first current according to heating furnace, find send as an envoy to the furnace temperature the fastest fuel quantity of rising and air capacity, after finding, just allow heating furnace work under this optimum condition, if fuel, air there occurs change again, system finds new the best combustion/empty proportioning combination again, and like this, whole heating process is just in optimal combustion state all the time, furnace temperature just rises, until target temperature with prestissimo.

From heating process, temperature rise speed is always more and more less, so when starting to find at every turn, be all that the temperature increase Δ T first measured in the unit interval this moment goes to find the maximum temperaturerise speed that can reach at present as starting point, after reaching target temperature temperature, just enter soaking zone and carry out steel billet heat insulating process, after reaching the temperature retention time of technological requirement, if tapping temperature now reaches the rolling temperature that roll line requires, just can carry out having tapped, be sent to milling train and carry out Rolling production.

Native system beneficial effect and advantage: the control technology of multiple-model integration utilizing native system and provide, native system is compared with other control mode, and the device integration of control system is high, has more practicality, can produce more reliably, reach energy-efficient, the object of safety and stability.

By in conjunction with the following drawings, after reading the detailed description of embodiment of the present invention, other features of the present invention, feature and advantage will become apparent.

Accompanying drawing explanation

Fig. 1 is a kind of steel rolling heating furnace integrated Control system architecture schematic diagram of the present invention;

Fig. 2 obtains working of a furnace diagnostic model process flow diagram in Fig. 1 steel rolling heating furnace integrated control system;

Fig. 3 obtains steel billet temperature Controlling model Establishing process figure in Fig. 1 steel rolling heating furnace integrated control system;

Fig. 4 obtains steel billet temperature handling procedure process flow diagram in Fig. 1 steel rolling heating furnace integrated control system;

Fig. 5 obtains best temperature rise program flow diagram () in Fig. 1 steel rolling heating furnace integrated control system;

Fig. 6 obtains best temperature rise program flow diagram (two) in Fig. 1 steel rolling heating furnace integrated control system.

Embodiment

Below in conjunction with accompanying drawing, the specific embodiment of the present invention is described in detail.

Fig. 1 is a kind of steel rolling heating furnace integrated Control system architecture schematic diagram of the present invention.

Comprise: SCS supervisory computer system 101, ES slip-stick artist's controller 102, OS operator's computing machine 103, CG computing machine gateway 104, SNET monitor network 105, FBI field-bus interface 106, FNET fieldbus networks 107, FD fieldbus instrument and utility appliance 108.

SCS supervisory computer system 101 is used for setting up fault diagnosis model, steel billet temperature Controlling model, the furnace temperature temperature rise optimizing control models of heater for rolling steel production run, various model carries out information fusion, the foundation of database, knowledge base, renewal and maintenance, realize advanced process control strategy, the optimization of system and cooperation control, and working of a furnace diagnosis, forecast and analysis can be carried out to heating furnace production run, guarantee safe production.

ES slip-stick artist's controller 102, carries out system generation and maintenance for field engineer to FCS, provides the establishment of the drafting of control engineering Shi Jinhang control loop configuration programming, man-machine interface, report making and special applications software.

OS operator's computing machine 103, for the operation of heater for rolling steel production run, supervision and management.For system provides heater for rolling steel production run man-machine interface (MMI), for user provides the picture of heater for rolling steel production run to be divided into general picture, special picture and supervisory frame etc., wherein general picture has heater for rolling steel production run overview panel, a series of paintings face, point picture, trend picture, alarm screen etc., special picture has main menu, data acquisition system (DAS) picture, Operating Guideline picture, control loop picture etc., supervisory frame has operator's operation note, process point alarm logging, system equipment status record, system equipment error logging, system equipment status, functional block gathers picture etc.Under the support of configuration software, first user draws and configuration heater for rolling steel production run picture, then picture file is downloaded to operator's computer run, operates, monitors and manage for process operator to production run.

CG computing machine gateway 104, for connecting monitor network 105 and production management network, realizes the intercommunication mutually between them.

SNET monitor network 105, for connecting FBI field-bus interface 106, OS operator's computing machine 103, ES slip-stick artist's controller 102, SCS supervisory control comuter 101 and CG computing machine gateway 104, carries out Signal transmissions.

FBI field-bus interface 106, has Cardbus NIC Cardbus and interchanger, under connect FNET fieldbus networks 107, on connect SNET monitor network 105, thus realize being interconnected of FNET fieldbus networks 107 and SNET monitor network 105.

FNET fieldbus networks 107, under connect FD fieldbus instrument and equipment 108, on connect FBI field-bus interface 106, carry out the exchange of on-site signal and control signal.

FD fieldbus instrument and utility appliance 108, include: signals collecting transmitter, actuator and signal converter, for the collection of heater for rolling steel control signal data, input, output, computing, control with communicate, and functional block is provided, at the scene bus to form heater for rolling steel production run control loop, form a distributed network control system.

(1) signals collecting transmitter

Signals collecting transmitter has the signal supervisory instrument such as temperature, pressure, flow, liquid level that heater for rolling steel is conventional, be made up of instrument circle card and bus circle card, instrument circle card completes sensor signal and amplifies and conversion, and by interface bus and bus circle card exchange information.Also have A/D conversion and interface circuit in addition, carry out the analog to digital conversion of collection signal, bus circle card realizes field bus protocol FF-H1 and the round exchange information of blocking of instrument, by bus interface and field bus communication, transform block is provided, Resource Block and functional block, adopt integrated circuit (IC) chip (ASIC), CPU, bus interface circuit and with instrument circle block the interface circuit forming exchange information, the application function of field bus protocol FF-H1 is realized by CPU software programming in bus circle card, the driving of the bus signals needed for Physical layer and data link layer is realized by integrated circuit (IC) chip (ASIC), send, the acceptance of signal, serial/parallel or the parallel/serial conversion of transmission data, the Code And Decode of serial data, the packing of information frame and unpacking, the functions such as the generation of Frame Check Sequence and verification.

(2) actuator

Actuator has electric control valve and pneumatic control valve.Be made up of instrument circle card and bus circle card, instrument circle card is for signal conversion and drives, and by interface bus and bus circle card exchange information, D/A conversion and interface circuit, carry out the digital-to-analog conversion of control signal, bus circle card realizes field bus protocol FF-H1 and the round exchange information of blocking of instrument, by bus interface and field bus communication, transform block, Resource Block and functional block are provided, adopt integrated circuit (IC) chip (ASIC), CPU, bus interface circuit and block with instrument circle the interface circuit forming exchange information.

(3) signal converter

Signal converter is used for the conversion of the signal between traditional analog instrument and fieldbus numeral instrument, mainly: a) receive 4mA ~ 20mADC current signal, then converts thereof into the applicable signal of FF-H1; B) receive the digital signal of FF-H1, then convert thereof into 4mA ~ 20mADC current signal.Traditional analogue instrument is made progressively to the transition of fieldbus numeral instrument by converter.

Fieldbus instrument has resource module, conversion module and functional module, resource module includes the characteristic such as type, memory size of equipment, conversion module includes the I/O characteristic of equipment, for from sensor reading certificate or to actuator issue an order, for functional module application provides interface.There is containing parameter in system in the parameter list of resource module and conversion module, without input and output parameter, the configuration of control loop can not be carried out.Functional module includes input, output, computing and control function block, form parameters input, parameter output, algorithm, interior containing parameter, incoming event and outgoing event, owing to there being input and output parameter, the configuration of heater for rolling steel production run control loop can be carried out.

The formation in Fieldbus Control loop is exactly the connection in fieldbus instrument between functional block, usually could form a control loop by the functional module of several fieldbus instruments, both can form simple control loop, and also can form complex control loop.For this reason, first carry out connecting configuration between functional module with configuration software, form configuration file; Then configuration file is downloaded in each fieldbus instrument, set up the annexation between functional module; In last bus at the scene, scheduling forms each functional block operation of control loop, carries out the Parameter transfer between functional module.

Fieldbus utility appliance has bus power source, source impedance conditioner, intrinsic safety barriter, terminal organ, repeater and bridge.

(1) bus power source: be used for as bus or field instrument are powered.

(2) source impedance conditioner: present high impedance to digital signal, prevents digital signal by bus power source short circuit.

(3) intrinsic safety barriter: it is the isolator of harbor and hazardous area.

(4) terminal organ: be used in the head end of transmission cable and the impedance matching box of end, terminal organ can prevent signal transmission distortion and bus two ends from producing signal wave reflection.

(5) repeater: be used for extending fieldbus segment.Repeater is an active Bus Powered Device or non-bus power-supply unit.

(6) bridge: for connecting the fieldbus segment of different transmission rates, or the network segment of different transmission medium is linked to be network.

Fig. 2 obtains working of a furnace diagnostic model process flow diagram in Fig. 1 steel rolling heating furnace integrated control system.

Concrete steps are as follows:

In step 201, model running starts;

In step 202, determine the input of Fuzzy Inference Model, output variable, namely selecting according to expertise and calculating affects larger variable as input variable for each concrete working of a furnace, and concrete working of a furnace grade is as output variable;

In step 203, determine each input, the variation range of output variable, quantification gradation and quantizing factor;

In step 204, in the quantized field of each input and output linguistic variable, define fuzzy subset;

In step 205, T-S model is utilized to obtain the correlation parameter of model.

And as follows based on the single order T-S fuzzy model of K rule:

R _i：IFx ₁isA _i1And…Andx _jisA _ijAnd…Andx _misA _im，Theny _i＝a _iz+b _i(1)

Z=[x in formula ₁..., x _j..., x _m] ^t, a _i=[a _i1... a _ij... a _im], i=1,2 ..., K; J=1,2 ..., m.R _irepresent the i-th rule, x _jrepresent the fuzzy subset of a jth input variable, y _irepresent the output valve of the i-th rule, a _i, b _ifor unknown parameter.

The output of T-S model, namely T-S fuzzy system defuzzifier is:

$\tilde{y}=\frac{\underset{i=1}{\overset{K}{\mathrm{\Σ}}}{\mathrm{\γ}}_i\left(z\right)y_i\left(z\right)}{\underset{i=1}{\overset{K}{\mathrm{\Σ}}}{\mathrm{\γ}}_i\left(z\right)}=\underset{i=1}{\overset{K}{\mathrm{\Σ}}}{\mathrm{\ω}}_i\left(z\right)(a_{i}z+b)---\left(2\right)$

${\mathrm{\ω}}_i\left(z\right)={\mathrm{\γ}}_i\left(z\right)/\underset{i=1}{\overset{K}{\mathrm{\Σ}}}{\mathrm{\γ}}_i\left(z\right)---\left(3\right)$

Wherein γ _iz () is the contribution rate that the i-th rule exports for T-S model, ω _iz () is normal contribution.

Calculate can obtain desired parameters by this model.

In step 206, defuzzification obtains concrete working of a furnace grade as output.

So far, a complete fuzzy control table is set up.Once detect out of order high-risk grade, working of a furnace diagnostic system just provides alarm, provides concrete operation measure for operating personnel according to expertise simultaneously.

Compared to additive methods such as neural networks, T-S model can detect fault more accurately, and the working time simultaneously needed is less, also achieves good effect in actual applications.

Fig. 3 obtains steel billet temperature Controlling model Establishing process figure in Fig. 1 steel rolling heating furnace integrated control system.

Steel billet temperature Controlling model is made up of basic steel billet Temperature Control Model and adjustment Correction and Control model two parts.

(1) first according to on-the-spot expert's priori, basic steel billet Temperature Control Model is set up:

According to calorifics formula, a given regretional analysis, the furnace temperature given by standard and various steel billet thickness and time inside furnace carry out the calculating of steel billet cardinal temperature parameter, and carry out regretional analysis by this result, Confirming model basic parameter, sets up the temperature controlled basic model of basic steel billet thus.

In heating furnace, existed as shown in the formula relation by the temperature of heating steel billet and soaking zone furnace temperature, steel billet time inside furnace:

Q _m＝S _z-B ₀e ^-AX(4)

In formula: Q _mthe medial temperature of-steel billet; S _zthe mean value of the upper and lower furnace temperature of-soaking zone; X-time inside furnace;

B ₀-constant; A-coefficient.

In fact affect the temperature factor of steel billet, except time inside furnace, it is also relevant with steel billet thickness.

The relation of steel billet thickness and coefficient A:

A＝c·h ⁿ(5)

In formula: the thickness of h-steel billet; C, n-constant.

Taken the logarithm in (5) formula both sides:

lnA＝nlnh+lnC(6)

Regression equation for regression coefficient A:

lnA＝α ₁lnh+α ₃t+α ₂lnt+α ₄(7)

:

A＝h ^α1·t ^α3·e ^α2t+α4(8)

Time inside furnace is represented, S with t _z-Q ₀the B of substitution formula (4) ₀, obtain:

Q _m＝S _z-(S _z-Q ₀)e ^-At(9)

$e^{-\mathrm{At}}=-\frac{Q_m-S_Z}{S_z-Q_0}---\left(10\right)$

Formula (8) is substituted into formula (10) obtain:

$\begin{array}{c}\frac{S_z-Q_m}{S_z-Q_0}=e^{-(\mathrm{h\α}1\•t^{\mathrm{\α}3+1}}\exp ({\mathrm{\α}}_{2}t+{\mathrm{\α}}_4)\·t\\ =\exp \{-h^{\mathrm{\α}1}\·t^{\mathrm{\α}3+1}\·\exp ({\mathrm{\α}}_2\·t+{\mathrm{\α}}_4)\}\end{array}---\left(11\right)$

Are taken the logarithm in formula (11) both sides:

$\ln \frac{S_z-Q_m}{S_z-Q_0}=-[h^{\mathrm{\α}1}\·t^{\mathrm{\α}3+1}\·\exp ({\mathrm{\α}}_{2}t+{\mathrm{\α}}_4)]---\left(12\right)$

$\ln \left(\ln \frac{S_z-Q_m}{S_z-Q_0}\right)=-[{\mathrm{\α}}_1\·\ln h+{\mathrm{\α}}_{2}t+({\mathrm{\α}}_3+1)\·\ln t]---\left(13\right)$

Select the steel billet thickness that adapts with concrete heating furnace and time inside furnace to combine, calculate the medial temperature of slab by analytical model, and with replacement (13) formula in Q _m, then the S in formula (13) is replaced with the soaking zone standard furnace temperature suitable for this heating furnace _z, the factor alpha in (12) formula ₁~ α ₄.

Finally obtain the essential part of steel billet temperature Controlling model:

Q _m＝S _z-(S _z-Q ₀)·exp{-h ^α1·t ^α3+1·exp(α ₂t+α ₄)}(14)

For the determination of model parameter, to carry out according to on-the-spot knowledge such as the usable range of the characteristic of heating furnace, thermal regulation, slab thickness and steel billet and possible time inside furnaces, ask factor alpha with regression analysis ₁~ α ₄, these coefficients are substituted into (14) formula, under given furnace temperature, the steel billet medial temperature of any thickness and time inside furnace can be calculated.

(2) again according to on-the-spot real-time data base content, combine in conjunction with various steel billet thickness and time inside furnace, calculate the modified value of each section of furnace temperature, draw adjustment and the retouch of Controlling model:

Essential part due to Controlling model carries out steel billet temperature calculating under a certain fixing standard temperature, each section of desired temperature has direct impact to steel billet temperature, the actual model used must adapt to the many variations of each section of furnace temperature setting value, and obtain the change of the steel billet temperature caused thus, therefore must above model be adjusted and be revised.

Because heating furnace is generally made up of four sections, and each section design temperature has impact in various degree to steel billet temperature, therefore the model of retouch must comprise the amendment type of corresponding four sections, and formula (15) below can be adopted as the adjustment retouch of model:

ΔQ _m＝ΔHZ ₁(β ₁+β ₂·h+β ₃·t+β ₄·h·t)+

ΔHZ ₂(β ₅+β ₆·h+β ₇·t+β ₈·h·t)+

ΔHZ ₃(β ₉+β ₁₀·h+β ₁₁·t+β ₁₂·h·t)+

ΔHZ ₄(β ₁₃+β ₁₄·h+β ₁₅·t+β ₁₆·h·t)+β ₁₇(15)

In formula: Δ Q _mafter the change of-set temperature value, the undulating quantity of steel billet temperature; T-time inside furnace; H-steel billet thickness;

Δ HZ1-preheating section design temperature changing value; Δ HZ2-mono-bringing-up section design temperature changing value;

Δ HZ3-bis-bringing-up section design temperature changing value; Δ HZ4-soaking zone design temperature changing value;

β ₁~ β ₁₇-coefficient.

Due to adjustment retouch, it will adjust the change of the steel billet temperature that modifying factor change setting furnace temperature causes, so the scheme of furnace temperature adjustment first will be solved, in conjunction with the knowledge of database, steel billet thickness and time inside furnace can be selected to carry out different combinations, then the calculating of steel billet temperature is carried out, steel billet temperature when combining with corresponding slab thickness during standard furnace temperature and time inside furnace again asks poor, just obtain the influence amount to steel billet temperature when design temperature fluctuates, design temperature before and after steel billet temperature variable quantity corresponding for these schemes and change is substituted into formula (15), carry out recurrence to calculate, can obtain adjusting the factor beta with retouch ₁~ β ₁₇.

(3) foundation of steel billet temperature Comprehensive Control model:

The final form of steel billet temperature Controlling model is made up of above-mentioned essential part and adjustment retouch, namely

$\begin{array}{c}T=\frac{1}{2}(S_{\mathrm{ZU}}+S_{\mathrm{ZL}})-[\frac{1}{2}(S_{\mathrm{ZU}}+S_{\mathrm{ZL}})-Q_0]\\ \×\exp \{-H^{A1}\·t_{\mathrm{TS}}^{A2}\·\exp (A_3\·t_{\mathrm{TS}}+A_4)\\ +\mathrm{\ΔHZ}1\·({\mathrm{\β}}_1+{\mathrm{\β}}_2\·H+{\mathrm{\β}}_3\·t_{\mathrm{TS}}+{\mathrm{\β}}_4\·H\·t_{\mathrm{TS}})\\ +\mathrm{\ΔHZ}2\·({\mathrm{\β}}_5+{\mathrm{\β}}_6\·H+{\mathrm{\β}}_7\·t_{\mathrm{TS}}+{\mathrm{\β}}_8\·H\·t_{\mathrm{TS}})\\ +\mathrm{\ΔHZ}3\·({\mathrm{\β}}_9+{\mathrm{\β}}_{10}\·H+{\mathrm{\β}}_{11}\·t_{\mathrm{TS}}+{\mathrm{\β}}_{12}\·H\·t_{\mathrm{TS}})\\ +\mathrm{\ΔHZ}4\·({\mathrm{\β}}_{13}+{\mathrm{\β}}_{14}\·H+{\mathrm{\β}}_{15}\·t_{\mathrm{TS}}+{\mathrm{\β}}_{16}\·H\·t_{\mathrm{TS}})+{\mathrm{\β}}_{17}\end{array}$

In formula: S _zU, S _zLthe top and the bottom reference temperature of-soaking zone; Q ₀steel billet temperature during-shove charge; H-steel billet thickness; t _tS-time inside furnace; Δ HZ1, Δ HZ2, Δ HZ3, Δ HZ4-are respectively the difference of each section of design temperature and reference temperature, that is: Δ HZi=T _ai-T _bi, wherein: T _aifor the design temperature of this section; T _bifor the reference temperature of this section; I=1 ~ 4 are segment number.

Steel billet temperature of coming out of the stove can be calculated thus.

Fig. 4 obtains steel billet temperature handling procedure process flow diagram in Fig. 1 steel rolling heating furnace integrated control system.

In step 401, flow process starts;

In step 402, run working of a furnace diagnostic routine, and carry out system call interception according to result;

In step 403, adjustment System, makes it to reach stable;

In step 404, carry out furnace temperature T signals collecting.

In step 405 to step 409, by the temperature signal T that collects with bringing-up section desired temperature T _ifcompare, if be less than desired temperature T _if, just this sample temperature T is saved in internal memory and goes, proceed temperature acquisition, complete same calculating process, and calculate furnace temperature changing value Δ Tk.

In step 410 to step 416, by the temperature signal T that collects with bringing-up section desired temperature T _ifcompare, if be greater than desired temperature T _ifsteel billet just enters soaking zone and is incubated, and calculate steel billet in the soaking zone time, determine the moment of tapping, then carry out the calculating of steel billet tapping temperature, if this temperature meets rolling requirements, just this steel billet is extracted out, be sent to rolling line to be rolled, otherwise heating steel billet is just nonconforming, steel billet re-starts heating.

Fig. 5 ~ Fig. 6 obtains best temperature rise program flow diagram in Fig. 1 steel rolling heating furnace integrated control system.

Optimal Control is carried out to heater for rolling steel production run temperature, be exactly want furnace temperature to rise with the fastest speed, need on the one hand to supply enough fuel (heavy oil and gas), suitable air to be supplied simultaneously, make fuel just can Thorough combustion, burned many, lack of air or burn less, air excess all can not obtain the fastest rate of rise in temperature.

In whole Furnace Production Process, need to go to regulate according to fuel at that time, air conditions, fuel/air mixture proportioning is combined and is in optimum condition all the time, just can obtain higher temperature rise speed.

In the present system, the best temperature rise adjustment process of heating furnace is carried out as follows:

First current according to heating furnace situation, find send as an envoy to the furnace temperature the fastest fuel quantity of rising and air capacity, after finding, heating furnace is just allowed to work under this optimum condition, if fuel, air there occurs change again, system is adjust fuel amount and air capacity again, find new the best combustion/empty proportioning combination, like this, whole heating process is just in optimal combustion state all the time, furnace temperature just rises, until target temperature with prestissimo.

From heating process, temperature rise speed is always more and more less, so when starting to find at every turn, all that the temperature increase Δ T first measured in the unit interval this moment goes to find the maximum temperaturerise speed that can reach at present as starting point, after reaching target temperature temperature, just enter soaking zone and carry out steel billet heat insulating process, after reaching the temperature retention time of technological requirement, if tapping temperature now reaches the rolling temperature that roll line requires, just can carry out having tapped.

On the basis of the process flow diagram shown in Fig. 2 to Fig. 6, the exploitation of application software can be carried out without the need to creationary work in conjunction with native system technician, carry out heater for rolling steel production run Optimal Control.

System provided by the present invention, in complex situations, effectively can carry out Comprehensive Control to heater for rolling steel production run, improve production efficiency and heating steel billet quality, reduce energy consumption, ensure that heating furnace runs with security and stability, thus reach the heater for rolling steel productive target of " high-quality, low consumption, high yield " and the control criterion of " safety, stable, equilibrium ".

Claims (3)

1. a steel rolling heating furnace integrated control system, comprise: SCS supervisory computer system [101], ES slip-stick artist's controller [102], OS operator's computing machine [103], CG computing machine gateway [104], SNET monitor network [105], FBI field-bus interface [106], FNET fieldbus networks [107], FD fieldbus instrument and utility appliance [108], is characterized in that:

SCS supervisory computer system [101] is used for setting up fault diagnosis model, steel billet temperature Controlling model, the furnace temperature temperature rise optimizing control models of heater for rolling steel production run, various model carries out information fusion, the foundation of database, knowledge base, renewal and maintenance, realize advanced process control strategy, the optimization of system and cooperation control, and can the production run working of a furnace be diagnosed, forecasts and be analyzed, guarantee safe production;

ES slip-stick artist's controller [102], for field engineer, system generation and maintenance are carried out to field bus system FCS, the establishment of the drafting of control engineering Shi Jinhang heater for rolling steel production run control loop configuration programming, man-machine interface, report making and special applications software is provided;

OS operator's computing machine [103], for the operation of heater for rolling steel production run, monitor and management, for system provides the man-machine interface of heater for rolling steel production run, the picture of the heater for rolling steel production run provided for user is divided into general picture, special picture and supervisory frame, wherein general picture has heater for rolling steel production run overview panel, a series of paintings face, point picture, trend picture, alarm screen, special picture has main menu, data acquisition system (DAS) picture, Operating Guideline picture, control loop picture, supervisory frame has operator's operation note, process point alarm logging, system equipment status record, system equipment error logging, system equipment status, functional block gathers picture, under the support of configuration software, first user draws the picture with configuration heater for rolling steel production run, again picture file is downloaded to operator's computer run, for process operator, heater for rolling steel production run is operated, monitor and management,

CG computing machine gateway [104], for connecting monitor network [105] and production management network, realizes the intercommunication mutually between them;

SNET monitor network [105], for connecting FBI field-bus interface [106], OS operator's computing machine [103], ES slip-stick artist's controller [102], SCS supervisory control comuter [101] and CG computing machine gateway [104], carry out Signal transmissions;

FBI field-bus interface [106], there are Cardbus NIC Cardbus and interchanger, for under connect FNET fieldbus networks [107], on connect SNET monitor network [105], realize being interconnected of FNET fieldbus networks [107] and SNET monitor network [105];

FNET fieldbus networks [107], under connect FD fieldbus instrument and equipment [108], on connect FBI field-bus interface [106], carry out the exchange of on-site signal and control signal;

FD fieldbus instrument and utility appliance [108], include: signals collecting transmitter, actuator and signal converter, for the collection of heater for rolling steel control signal data, input, output, computing, control with communicate, and functional block is provided, at the scene bus to form the control loop of heater for rolling steel production run, form a distributed network control system.

2., for a control method for a kind of steel rolling heating furnace integrated control system as claimed in claim 1, it is characterized in that, comprise the following steps:

(1) heater for rolling steel production run working of a furnace diagnostic model is analyzed;

(2) foundation of steel billet temperature Controlling model;

(3) operation of the best Temperature Rise Model of heating furnace.

3. the control method of a kind of steel rolling heating furnace integrated control system according to claim 2, it is characterized in that the best Temperature Rise Model of heating furnace is set up is realize by performing following steps:

(1) first current according to heating furnace situation, finds send as an envoy to the furnace temperature the fastest fuel quantity of rising and air capacity;

(2) heating furnace works under this fuel quantity and air capacity assembled state;

(3) if fuel, air there occurs change again, system just readjusts fuel quantity and air capacity, finds new the best combustion/empty proportioning combination;

(4) heating furnace is according to new combustion/empty proportioning combination, continues to control furnace temperature heating process, until target temperature;

Like this, whole heating process is just in optimal combustion state all the time, and furnace temperature just rises with prestissimo.